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Harley Davidson 2006 Sportster XLH MODELS. Service Manual - page 34

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x0522a3x

BK

LtGN/V

O

LtGN/V

O/W

BN/GY

GY

BK

Odometer

reset switch

BN/GY

1

2

3

4 5 6 7 8 9 10 11 12

[39B]

[30B]

1

2

3

4 5 6 7 8 9 10 11 12

1

2

3

4 5 6 7 8 9 10 11 12

1

2

3

4 5 6 7 8 9 10 11 12

[39A]

[30A]

Speedometer

TSM/TSSM

[108B]

1

2

3

4 5 6 7 8 9 10 11

12

1

2

3

4 5 6 7 8 9 10 11

12

[108A]

Tachometer

[20B]

(if equipped)

1

2

3

4

5 67 8 9

10

11 12

[20A]

1

2

3

4

5 67 8 9

10

11 12

BK

15A

ACC

Data link

connector

BN/GY

15A

1

1

BATT

BK

2

2

LtGN/V

3

3

15A

INST

4

4

GY

15A

[91A]

[91B]

IGN

Fuse

block

LtGN/V

[10B]

1

2

3

4

5

6

7

8

9

10

11

12

[10A]

Ignition Control Module (ICM)

Figure 3-36. Serial Data Circuit

Table 3-21. Wire Harness Connectors in Figure 3-36.

NO.

DESCRIPTION

TYPE

LOCATION

[10]

Ignition control module

12-place Deutsch

under seat

[20]

Instruments

12-place Deutsch

under fuel tank

[30]

TSM/TSSM

12-place Deutsch

under battery

[39]

Speedometer

12-place Packard

back of speedometer

[91A]

Data link connector

4-place Deutsch

behind left side cover

[108]

Tachometer (if equipped)

12-place Packard

back of tachometer

2006 Sportster: TSM & TSSM

3-63

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Test 3.20

LOSS OF ICM SERIAL DATA: DTC U1016, U1255

Can you read ICM hardware part number?

See 2.3 SPEEDOMETER SELF DIAGNOSTICS.

YES

NO or “No Rsp”

1

1

While wiggling harness, check continuity

Check continuity between Breakout

between Breakout Box cavity 3 (gray) and

Box cavity 3 (gray) and Breakout

Breakout Box cavity 12 (black).

Box cavity 12 (black).

Does continuity fluctuate?

Is continuity present?

YES

NO

YES

NO

Clear DTCs. Test ride.

Repair intermittent

Replace ICM.

Repair open on

Did DTC U1016 return?

on Lt GN/V wire.

Reprogram and learn

Lt GN/V wire.

password.

YES

NO

Replace ICM.

No trouble found.

Reprogram and learn

password.

Clear DTCs using speedometer self diagnostics. See

3.10 SPEEDOMETER SELF DIAGNOSTICS. Confirm

proper operation with no security lamp.

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2006 Sportster: TSM & TSSM

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DTC U1097, U1255

3.21

GENERAL

11333

1

2

Loss of Speedometer Serial Data

The serial data line provides a means for the speedometer,

ICM and TSM/TSSM to communicate their current status.

When all operating parameters are within specifications, a

state of health message is sent between the components. A

diagnostic trouble code

(DTC) U1097 indicates that the

speedometer is not capable of sending this state of health

message. A DTC U1255 indicates that no messages were

present during power up of the current key cycle. A DTC

U1097 indicates that there was communication on the data

bus since power up, but communication was lost or inter-

rupted during that key cycle.

1.

TSM/TSSM

2.

TSM/TSSM connector [30]

Table 3-22. Code Description

Figure 3-37. TSM/TSSM Location

DTC

DESCRIPTION

Loss of all speedometer serial data

U1097

(state of health)

U1255

Missing message at speedometer

DIAGNOSTICS

Diagnostic Notes

The reference numbers below correlate with the circled num-

bers on the 3.21 flow chart.

1. Connect BREAKOUT BOX (Part No. HD-42682) as fol-

lows:

a. Mate gray pin housing on Breakout Box with TSM/

TSSM harness connector [30B]. Leave TSSM [30A]

disconnected.

b. Mate black pin housing on Breakout Box with har-

ness connector [39B] using INSTRUMENT HAR-

NESS ADAPTERS

(Part No.HD-46601). Leave

speedometer [39A] disconnected.

2006 Sportster: TSM & TSSM

3-65

HOME

x0522a3x

BK

LtGN/V

O

LtGN/V

O/W

BN/GY

GY

BK

Odometer

reset switch

BN/GY

1

2

3

4 5 6 7 8 9 10 11 12

[39B]

[30B]

1

2

3

4 5 6 7 8 9 10

11

12

1

2

3

4 5 6 7 8 9 10 11 12

1

2

3

4 5 6 7 8 9 10

11

12

[39A]

[30A]

Speedometer

TSM/TSSM

[108B]

1

2

3

4 5 6 7 8 9 10

11

12

1

2

3

4 5 6 7 8 9 10

11

12

[108A]

Tachometer

[20B]

(if equipped)

1

2

3

4

5 67 8

9

10

11 12

[20A]

1

2

3

4

5 67 8

9

10

11 12

BK

15A

ACC

Data link

connector

BN/GY

15A

1

1

BATT

BK

2

2

LtGN/V

3

3

15A

INST

4

4

GY

15A

[91A]

[91B]

IGN

Fuse

block

LtGN/V

[10B]

1

2

3

4

5

6

7

8

9

10

11

12

[10A]

Ignition Control Module (ICM)

Figure 3-38. Serial Data Circuit

Table 3-23. Wire Harness Connectors in Figure 3-38.

NO.

DESCRIPTION

TYPE

LOCATION

[10]

Ignition control module

12-place Deutsch

under seat

[20]

Instruments

12-place Deutsch

under fuel tank

[30]

TSM/TSSM

12-place Deutsch

under battery

[39]

Speedometer

12-place Packard

back of speedometer

[91A]

Data link connector

4-place Deutsch

behind left side cover

[108]

Tachometer (if equipped)

12-place Packard

back of tachometer

3-66

2006 Sportster: TSM & TSSM

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Test 3.21

LOSS OF SPEEDOMETER SERIAL DATA: DTC U1097, U1255

IMPORTANT!

Always perform Initial Diagnostic Check first.

See 3.9 INITIAL DIAGNOSTIC CHECK: TSM/TSSM

Can you read TSM/TSSM hardware Part No.?

See 4.5 SPEEDOMETER SELF DIAGNOSTICS.

YES

NO or “No rsp”

1

1

While wiggling harness, check for

Check for continuity between

continuity between Breakout Box

Breakout Box cavity 3 (gray)

cavity 3 (gray) and cavity 2 (black).

and cavity 2 (black).

Is continuity present?

Is continuity present?

YES

NO

YES

NO

Clear DTCs. Test Ride.

Repair intermittent on

Replace speedometer.

Repair open on

Did DTC U1097 or

Lt GN/V wire.

Lt GN/V wire.

U1255 return?

YES

NO

Replace speedometer

No trouble found.

Clear DTCs using speedometer self diagnostics. See

3.10 SPEEDOMETER SELF DIAGNOSTICS. Confirm

proper operation with no security lamp.

2006 Sportster: TSM & TSSM

3-67

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DTC U1300, U1301 OR BUS ER

3.22

GENERAL

10073

1

Serial Data Low or Serial Data Open/High

See Figure 3-39. The typical serial data voltage range is 0

4

5

volts (inactive) to 7 volts (active). Due to the short pulse, volt-

ages will be much lower on a DVOM. In analog mode, a

DVOM reading serial data will show continuous voltage when

active, typically 0.6-0.8 volts. The range for acceptable opera-

tions is 0-7.0 volts.

3

2

Table 3-24. Code Description

DTC

DESCRIPTION

U1300

Serial data low

1.

Terminal 1: no connection

2.

Terminal 2: ground (BK)

U1301

Serial data open/high

3.

Terminal 3: serial data (LtGN/V)

4.

Terminal 4: power (GY)

5.

Protective cap

DIAGNOSTICS

Figure 3-39. Data Link Connector [91A] Terminals

Diagnostic Tips

● If serial data is shorted, these diagnostic trouble codes

(DTCs) will automatically cause the check engine lamp

to illuminate. The odometer will read “Bus Er” in this con-

dition.

● DTCs P1009 and P1010 may accompany DTCs U1300

and U1301.

Diagnostic Notes

If a U1300, U1301 or “BUS Er” is present, perform diagnostic

procedures listed in 4.10 STARTS THEN STALLS.

3-68

2006 Sportster: TSM & TSSM

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Table 3-26. Setting TSM/TSSM and ICM Password

NO.

ACTION

CONFIRMATION

NOTES

Ignition must be turned off for at least 15

With ignition turned off, Check Engine

seconds.

Lamp and Security Lamp will be off.

Install new TSM/TSSM or ICM. Perform

1

all steps under 3.3 TSM/TSSM VEHICLE

DELIVERY.

2

Set RUN/OFF switch to RUN.

Verify Check Engine Lamp and Security

TSM/TSSM enables starter

3

Turn IGN key ON.

Lamp illuminate and then turn off.

relay.

Password has not been

Engine starts and stalls. Check Engine

4

Attempt normal start one time.

learned. ICM sets DTC

Lamp illuminates and stays on.

P1009.

ICM enters Password Learn-

ing mode for ten minutes. Do

Wait ten seconds. Security lamp will illu-

not cycle ignition switch or

5

Security Lamp illuminates.

minate and stay on.

interrupt vehicle power or

Password Learn will be

unsuccessful.

6

Wait until Security Lamp turns off.

This takes ten minutes

Quickly (within two seconds) turn IGN

ICM must not be allowed to

7

key OFF-ON.

shut down

8

Wait until Security Lamp turns off.

This takes ten minutes

Quickly (within two seconds) turn IGN

ICM must not be allowed to

9

key OFF-ON.

shut down

10

Wait until Security Lamp turns off.

This takes ten minutes

Quickly (within two seconds) turn IGN

ICM must not be allowed to

11

key OFF-ON.

shut down

Turn IGN key OFF. Wait 15 seconds

before turning IGN on. Turn IGN switch

12

ON and start engine to confirm success-

ful Password Learn procedure. Clear

diagnostic trouble codes.

Perform all steps under 3.3 TSM/TSSM

13

VEHICLE DELIVERY.

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2006 Sportster: TSM & TSSM

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TSSM MAINTENANCE

3.24

GENERAL

o0235xox

1

2

The TSSM system uses batteries in the key fob and security

siren. These are the only parts requiring periodic mainte-

nance.

KEY FOB

Schedule

3

Replace the key fob battery every 2 years.

1. Battery

Battery Replacement

2. Battery contact

1. Open the key fob case.

3. Circuit board

a. Place a thin blade between the 2 halves of the case.

Figure 3-40. Open Key Fob Case

b. Slowly twist the blade.

2. See Figure 3-40. Replace battery (1).

a. Remove the original battery.

o0234xox

b. Install a new battery with the positive (+) side down.

Use a Panasonic^® 2032 or equivalent.

3. See Figure 3-41. Align case and circuit board as shown.

Snap case halves together.

4. While standing next to the motorcycle, press and hold

the key fob button for 10-15 seconds until the security

system responds with two turn signal flashes/siren

chirps.

Figure 3-41. Key Fob Assembly

2006 Sportster: TSM & TSSM

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SECURITY SIREN (IF INSTALLED)

7867

Schedule

The siren’s internal 9-volt battery is rechargeable and does

not need to be replaced on a regular basis. Battery life under

normal conditions is approximately three to six years.

NOTE

The internal siren battery may not charge if the vehicle’s bat-

tery is less than 12.5 volts.

1

2

3

Battery Replacement

1.

Disarm system and remove siren. See Chapter 7 of the

1.

Cover

Sportster Models Service Manual for removal procedure.

2.

Battery

3.

Connector [142A]

2.

See Figure 3-42. Remove battery cover (1).

a. Place the siren module on a flat and sturdy table

Figure 3-42. Siren Battery Compartment

with the potted section (area with epoxy covering cir-

cuit board) facing up and towards you.

b. Position a knife blade at a 45 degree angle to the

7866

long side of the siren case. Insert the knife blade

between the siren case and battery cover at one of

the two accessible corners of the battery cover.

Keep the blade slightly higher towards the battery

cover as this helps keep the blade away from the

battery seal.

c. Slowly twist the blade towards the battery cover and

the cover will pop off.

NOTE

For protection against corrosion, battery terminals and bat-

tery clip are covered with a special grease. Do not wipe away

this substance. Apply all available existing grease to termi-

nals on new battery. If more grease is needed, use ELECTRI-

CAL CONTACT LUBRICANT (Part No. 99861-02).

3.

See Figure 3-43. Replace battery by removing old bat-

tery from polarized battery clip. Install a new 9 volt nickel

metal hydride battery. See the Sportster Parts Catalog

for the correct part number.

Figure 3-43. Siren Battery

NOTE

Only a nickel metal hydride nine-volt battery should be used

in the siren.

4.

See Figure 3-42. Reinstall battery cover (1).

a. Carefully replace the rubber seal.

b. Align battery cover (1) with case placing round cor-

ners on cover away from connector [142A]. Snap

cover into place.

5.

Install siren and check operation. If siren is working prop-

erly, it will respond with two chirps after receiving the arm

command.

3-72

2006 Sportster: TSM & TSSM

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SPECIFICATIONS

4.1

10062

Table 4-1. Ignition Specifications

IGNITION

DATA

1

Spark timing advance

10°-58° BTDC (range)

(883 DOM/California)

Spark timing advance

0°-58° BTDC (range),

(all except 883 DOM/California)

10° BTDC @ 1000 RPM

2

Idle speed

1000 ± 50 RPM

Spark plug size

12 mm

0.038-0.043 in

Spark plug gap

0.97-1.09 mm

Harley-Davidson

1.

Oil tank

Spark plug type

No. 6R12 (no substitute)

2.

Relay/fuse block

Ignition coil primary

Figure 4-1. System Fuse Block (Behind Left Side Cover)

2.5-3.1 ohms

resistance

Ignition coil secondary

10,000-12,500 ohms

resistance

10071

2

5

1

Table 4-2. Fuse Specifications

RATING

CIRCUIT

COLOR

(AMPERES)

System Fuses

Maxi-Fuse

30

Orange

6

Ignition

15

Blue

3

4

7

Lighting

15

Blue

Instruments

15

Blue

1. Starter relay

2. Accessories fuse

Accessory

15

Blue

3. Battery fuse

Battery

15

Blue

4. Lights fuse

5. Ignition fuse

6. Instruments fuse

7. Spare fuse

Figure 4-2. Fuses

2006 Sportster: Engine Management

4-1

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DIAGNOSTIC INTRODUCTION

4.2

SYSTEM PROBLEMS

x0523x3x

All system problems fall into at least one of three general cat-

egories.

No Start

The engine cranks over freely, but will not start. This does not

include situations where the engine will not crank, such as a

bad starter, dead battery, etc. This condition assumes that all

obvious checks (fuel in tank, etc.) have been made.

Poor Performance

The engine starts but there are performance problems. These

problems may include poor fuel economy, rough idle, engine

misfire, engine hesitation, severe spark knock, etc.

Check Engine Lamp

See Figure 4-3. The check engine lamp indicates the ignition

control module (ICM) has determined a fault condition exists.

There may also be starting or performance problems.

Figure 4-3. Check Engine Lamp

RESOLVING PROBLEMS

To resolve system problems, five basic steps are involved. In

order of occurrence, they are:

1.

Check for diagnostic trouble codes (DTCs) by observing

check engine lamp. See 4.3 CHECKING FOR DIAG-

NOSTIC TROUBLE CODES.

2.

Retrieve DTCs using Speedometer self diagnostics. See

4.5 SPEEDOMETER SELF DIAGNOSTICS

3.

Diagnose system problems. This involves using special

tools and the diagnostic flow charts in this section.

4.

Correct problems through the replacement and/or repair

of the affected components.

5.

After repairs are performed, the work must be validated.

This involves clearing the DTCs and confirming proper

vehicle operation as indicated by the behavior of the

check engine lamp.

4-2

2006 Sportster: Engine Management

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CHECKING FOR DIAGNOSTIC TROUBLE CODES

4.3

CHECK ENGINE LAMP

11526

See Figure 4-3. To diagnose system problems, begin by

2

3

observing the behavior of the check engine lamp.

NOTE

See Figure 4-4. “Key ON” means that the ignition key is

1

turned to IGNITION and the engine stop switch is set to RUN

(although the engine is not running).

When the ignition switch is turned ON, the check engine lamp

will illuminate for approximately four seconds and then turn

off.

1. If the check engine lamp is not illuminated at key ON or if

it fails to turn OFF after the initial four second period, see

4.5 SPEEDOMETER SELF DIAGNOSTICS.

2. If the check engine lamp illuminates late (after 20 sec-

onds), the problem is most likely a serial data bus failure.

1.

Ignition OFF

Test for diagnostic trouble codes (DTCs) using speedom-

2.

ACC ON

eter self diagnostics. See 4.5 SPEEDOMETER SELF

3.

Ignition ON

DIAGNOSTICS.

Figure 4-4. Ignition Switch

3. If the check engine lamp fails to turn OFF after the initial

four second period, a problem exists in the instrumenta-

tion. See 4.5 SPEEDOMETER SELF DIAGNOSTICS.

4. See Figure 4-6. After the check engine lamp turns off fol-

lowing the first four-second illumination period, one of

three events may occur:

a. The lamp remains off. This indicates there are no

current fault conditions or stored DTCs currently

detected by the ICM.

b. The lamp remains off for only four seconds and then

illuminates for an eight-second period. This indi-

cates a DTC is stored, but no current DTC exists.

c. The lamp remains off for only four seconds and then

illuminates and remains illuminated beyond the

eight-second period. This indicates a current DTC

exists.

See CODE TYPES which follows for a complete description

of DTC formats.

NOTE

DTCs relating to the ignition coil can only be fully diagnosed

during actuation. For example, a problem with the ignition coil

will be considered a current fault even after the problem is

corrected, since the ignition control module will not know of its

resolution until after the coil is exercised by vehicle start

sequence. In this manner, there may sometimes be a false

indication of the current DTC.

2006 Sportster: Engine Management

4-3

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SECURITY LAMP

x0523x3x

See Figure 4-5. To diagnose turn signal module (TSM) or turn

signal security module (TSSM) system problems, begin by

observing the behavior of the security lamp.

NOTES

● To provide an indication of TSM/TSSM DTCs, the secu-

rity lamp is enabled on all models.

● See Figure 4-4. “Key ON” means that the ignition key is

turned to IGNITION and the engine stop switch is set to

RUN (although the engine is not running).

When the ignition switch is turned ON, the security lamp will

illuminate for approximately four seconds and then turn off.

1.

If the security lamp is not illuminated at Key ON, the

problem is likely to be an instrument failure. See 4.5

SPEEDOMETER SELF DIAGNOSTICS.

Figure 4-5. Security Lamp

2.

If the security lamp illuminates late (after 20 seconds),

the problem is most likely a serial data bus failure. Test

for DTCs using speedometer self diagnostics. See 4.5

CODE TYPES

SPEEDOMETER SELF DIAGNOSTICS.

3.

If the security lamp fails to turn OFF after the initial four

There are two types of DTCs: current and historic. If a DTC is

second period, a problem exists in the instrumentation.

stored, it can be read using either Digital Technician or the

See 4.5 SPEEDOMETER SELF DIAGNOSTICS.

speedometer self diagnostics.

All DTCs reside in the memory of the ICM or TSM/TSSM until

4.

See Figure 4-6. After the security lamp turns off following

the DTC is cleared using the speedometer self diagnostics or

the first four second illumination period, one of three

a total of 50 trips has elapsed. A trip consists of a start and

events may occur:

run cycle, the run cycle lasting at least 30 seconds. After the

50 trip retention period, the DTC is automatically erased from

a. The lamp remains off. This indicates there are no

memory providing that no subsequent faults of the same type

current fault conditions or stored DTCs currently

are detected in that period.

detected by the TSM/TSSM.

b. The lamp stays off for only four seconds and then

Current

comes back on for an eight-second period. This indi-

Current DTCs are those which presently disrupt motorcycle

cates a DTC is stored, but no current DTC exists.

operation. Refer to the appropriate flow charts for solutions.

c. If the lamp remains on beyond the eight-second

Historic

period, a current DTC exists.

If a particular problem happens to resolve itself, the active

5.

See CODE TYPES which follows for a complete descrip-

status problem is dropped and it becomes a historic fault

tion of DTC formats.

rather than a current fault.

NOTE

Historic DTCs can only be retrieved using a computer based

diagnostic package called Digital Technician (Part No. HD-

Some DTCs can only be fully diagnosed during actuation. For

44750).

example, a problem with the ignition coil will be considered a

Historic DTCs are stored for a length of time to assist in the

current fault even after the problem is corrected, since the

diagnosis of intermittent faults. The check engine lamp will

ICM will not know of its resolution until after the coil is exer-

not indicate the existence of only historic DTCs.

cised by the vehicle start sequence. In this manner, there

may sometimes be a false indication of the current DTC.

It is important to note that historic DTCs may also be present

whenever the system indicates the existence of a current

fault. See MULTIPLE DIAGNOSTIC TROUBLE CODES if

multiple DTCs are found.

Diagnostic charts are designed for use with current DTCs and

as a result they frequently suggest part replacement. When

diagnosing a historic DTC the charts can be helpful but

should not lead to part replacement without verification the

part is faulty.

4-4

2006 Sportster: Engine Management

HOME

ON

4 Sec.

A

Lamp OFF: No Current or Historic DTCs

OFF

Key ON

Lamp ON 8 Seconds:

Only Historic DTCs Exist

ON

4 Sec.

8 Sec.

B

Lamp OFF

OFF

4 Sec.

Key ON

Lamp Remains ON: Current DTC *

ON

4 Sec.

C

4 Sec.

OFF

Key ON

* Historic DTCs May Also Exist

Figure 4-6. Check Engine and Security Lamp Operation

RETRIEVING DIAGNOSTIC

MULTIPLE DIAGNOSTIC

TROUBLE CODES

TROUBLE CODES

The engine management system provides two levels of diag-

While it is possible for more than one fault to occur and set

nostics.

more than one DTC, there are several conditions which may

result in one fault setting multiple DTCs.

● The most sophisticated mode employs a computer

based diagnostic package called DIGITAL TECHNICIAN

Serial data DTCs

(DTC U1016, U1064, U1097, U1255,

(Part No. HD-44750).

U1300 and U1301) may be accompanied by other DTCs.

Always correct the serial data DTCs before resolving other

● The second mode requires using the speedometer self

DTCs.

diagnostics. See 4.5 SPEEDOMETER SELF DIAGNOS-

TICS.

For proper resolution of multiple DTCs refer to diagnostic

trouble code priority chart page 4-8,Table 4-7.

2006 Sportster: Engine Management

4-5

HOME

Table 4-7. Diagnostic Trouble Codes (DTCs) and Fault Conditions

DTC NO.

PRIORITY

FAULT CONDITION

RELEVANT TOPIC

P0106

16

MAP sensor rate-of-change error

4.13 DTC P0106, P0107, P0108

P0107

17

MAP sensor failed open/low

4.13 DTC P0106, P0107, P0108

P0108

18

MAP sensor failed high

4.13 DTC P0106, P0107, P0108

P0371

13

crankshaft position sensor shorted low

4.14 DTC P0371, P0372, P0374

P0372

14

crankshaft position sensor shorted high

4.14 DTC P0371, P0372, P0374

Crankshaft position sensor not detected/

P0374

15

4.14 DTC P0371, P0372, P0374

cannot synchronize

P0501

23

VSS failed low

4.15 DTC P0501, P0502

P0502

24

VSS failed high/open

4.15 DTC P0501, P0502

P0562

21

system voltage low

4.16 DTC P0562, P0563

P0563

22

system voltage high

4.16 DTC P0562, P0563

P0602

1

Calibration memory error

4.17 DTC P0602, P0603, P0604, P0605, P0607

P0603

2

EEProm memory error

4.17 DTC P0602, P0603, P0604, P0605, P0607

P0604

3

RAM memory error

4.17 DTC P0602, P0603, P0604, P0605, P0607

P0605

4

Program memory error

4.17 DTC P0602, P0603, P0604, P0605, P0607

P0607

5

A to D error

4.17 DTC P0602, P0603, P0604, P0605, P0607

P1009

11

Incorrect password

4.18 DTC P1009, P1010

P1010

12

Missing password

4.18 DTC P1009, P1010

P1351

19

Ignition coil driver front low/open

4.19 DTC P1351, P1352, P1354, P1355

P1352

20

Ignition coil driver front high

4.19 DTC P1351, P1352, P1354, P1355

U1064

9

Lost TSM/TSSM communication

4.20 DTC U1064

U1097

10

Lost speedometer communication

4.21 DTC U1097

U1300

7

Serial data shorted low

4.10 STARTS THEN STALLS

U1301

8

Serial data shorted high

4.10 STARTS THEN STALLS

“BUS Er”

6

serial data bus shorted low/open/high

4.10 STARTS THEN STALLS

4-8

2006 Sportster: Engine Management

HOME

x0522a3x

BK

LtGN/V

O

LtGN/V

O/W

BN/GY

GY

BK

Odometer

reset switch

BN/GY

1

2

3

4 5 6 7 8 9 10 11 12

[39B]

[30B]

1

2

3

4 5 6 7 8 9 10 11 12

1

2

3

4 5 6 7 8 9 10 11 12

1

2

3

4 5 6 7 8 9 10 11 12

[39A]

[30A]

Speedometer

TSM/TSSM

[108B]

1

2

3

4 5 6 7 8 9 10 11

12

1

2

3

4 5 6 7 8 9 10 11

12

[108A]

Tachometer

[20B]

(if equipped)

1

2

3

4

5 67 8 9

10

11 12

[20A]

1

2

3

4

5 67 8 9

10

11 12

BK

15A

ACC

Diagnostic link

connector

BN/GY

15A

1

1

BATT

BK

2

2

LtGN/V

3

3

15A

INST

4

4

GY

15A

[91A]

[91B]

IGN

Fuse

block

LtGN/V

[10B]

1

2

3

4

5

6

7

8

9

10

11

12

[10A]

Ignition Control Module (ICM)

Figure 4-7. Serial Data Circuit

Table 4-8. Wire Harness Connectors in Figure 4-7.

NO.

DESCRIPTION

TYPE

LOCATION

[10]

Ignition control module (black)

12-place Deutsch

under seat

[20]

Instruments

12-place Deutsch

under fuel tank

[30]

TSM/TSSM

12-place Deutsch

cavity in bottom of battery tray

[39]

Speedometer

12-place Packard

back of speedometer

[91A]

Diagnostic link

4-place Deutsch

behind left side cover

[108]

Tachometer

12-place Packard

back of tachometer

2006 Sportster: Engine Management

4-9

HOME

Initial Diagnostic Check (Part 1 of 3)

Does engine

start?

YES.

YES.

NO.

NO.

Starts and runs.

Starts, then stalls.

Cranks, but will not start.

Engine will not crank.

Check for DTCs. See 4.5

See 4.10 STARTS

See 4.9 ENGINE CRANKS

See 1.2 STARTING

SPEEDOMETER SELF

THEN STALLS.

BUT WILL NOT START.

SYSTEM DIAGNOSIS.

DIAGNOSTICS

Were DTCs found?

NO

NO

YES

Unable to enter

No codes

diagnostic mode.

displayed.

2

Refer to applicable DTC priority

With ignition switch OFF, press and

For a list of symptoms that

chart. All DTCs are listed by

release odometer reset switch.

may not set diagnostic

priority in Table 4-7.

Does odometer display appear with

trouble codes, refer to

display backlighting?

Table 3-10.

YES

NO

1

Check for continuity to ground at

Breakout Box cavity 7 (black). Wiggle

harness during continuity check.

Is continuity present?

STOP

Go to Initial Diagnostic

Check (Part 2 of 3).

YES

NO

Check for battery voltage at Breakout Box

Locate and

cavity 5 (black) while wiggling harness.

repair open.

Is battery voltage continuously present?

YES

NO

With ignition switch OFF and speedometer

Locate and

connector [39] disconnected, check continuity

repair open.

between Breakout Box cavities 8 and 11 (black).

Is continuity present when speedometer reset

switch is depressed and infinity when released?

YES

NO

Replace Speedometer.

Replace speedometer

reset switch.

4-10

2006 Sportster: Engine Management

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